98 Unit injector system Installation and drive

Unit injector system (UIS)

In the unit injector system (UIS), the fuel-
injection pump, high-pressure solenoid
valve and injection nozzle form a single
unit. The compact construction – with
very short high-pressure lines integrated
in the component between pump and
­nozzle – makes it easier to deliver higher
injection pressures compared with other
fuel-injection systems because the com-
1) The compression pression volume 1) and thus the compres-
volume is the fuel sion losses are lower. The peak pressure in
volume which is
the UIS currently varies, depending on the
compressed
type of pump, between 1,800 and 2,200 bar.
Installation and drive
Each cylinder has its own unit injector (UI),
which is installed directly in the cylinder
head (Fig. 1). For passenger cars, there are
two types of unit injector (UI-1, UI-2), which –
while having an identical function – differ in
size. In a 2-valve engine, the UI‑1 is secured
using a clamping block at an angle of ap-
prox. 20° in the engine's cylinder head. In a
4-valve engine, the smaller injector (UI-2)
is used on account of the smaller amount of
space available; this injector is secured ver-
tically in the cylinder head with anti-fatigue
bolts.
The engine camshaft (2) has an actuating
cam for each unit injector, the particular
cam lift being transferred to the pump
plunger (6) by a rocker arm (1). The injec-
tion curve is influenced by the shape of the
actuating cams. These are shaped so that
the pump plunger moves more slowly when
fuel is taken in (upward movement) than
during injection (downward movement) in
order, on the one hand, to prevent air from
being accidentally drawn in and, on the
other hand, to achieve a high delivery rate.
Torsional vibration is induced in the cam-
shaft by the forces applied to it during
operation, and adversely affects injection

1 Installation of unit injector (commercial vehicle)

1 6

Fig. 1
1 Rocker arm
2 Engine camshaft
5
3 Plug
« UMK1736-2Y

4 Unit injector 7
5 Injection nozzle
6 Pump plunger
7 Engine combustion
chamber

K. Reif (Ed.), Diesel Engine Management, Bosch Professional Automotive Information,

DOI 10.1007/978-3-658-03981-3_10, © Springer Fachmedien Wiesbaden 2014
 Unit injector system Design 99

characteristics and injected-fuel-quantity item 7) is integrated in the stem of the unit

metering. It is therefore imperative that in
order to reduce these vibrations the indi-
vidual-pump drives are designed to be as
rigid as possible (this applies to the cam-
shaft drive, the camshaft itself, the rocker
arm, and the rocker-arm bearings).
The unit injector is installed in the en-
gine’s cylinder head and is therefore subject
to very high temperatures. It is cooled by
relatively cool fuel flowing back to the low-
pressure stage.
Design
Fuel is supplied to the UI for passenger cars
through roughly 500 laser-drilled inlet pas-
sages in the steel sleeve of the injector. The
fuel is filtered by the passages, which have a
diameter of less than 0.1 mm.
The unit-injector body assembly serves
as the pump barrel. The nozzle (Fig. 2,
injector. The stem and body assembly are
connected to each other by means of a
­retaining nut (13).
The return spring (1) forces the pump
plunger against the rocker arm (8) and the
rocker arm against the actuating cam (9).
This ensures that pump plunger, rocker arm
and cam are always in contact during actual
operation.
In the unit injector for commercial vehicles,
the solenoid valve is integrated in the injec-
tor. In the UI for passenger cars, however,
it is mounted externally on the pump body
on account of the injector's smaller dimen-
sions.
The design of the injector for passenger
cars and commercial vehicles is shown on
the following pages.

2 Installation of unit injector in cylinder head (commercial vehicle)

1 Fig. 2
11 Return spring
9 12 Plug
2 13 High-pressure
chamber
3 10 (element chamber)
14 Solenoid coil
4
5 15 Solenoid-valve body
11 16 Solenoid-valve
needle
6 12
17 Injection nozzle
18 Rocker arm
19 Actuating cam
« UMK1743-2Y

10 Clamping element
13 11 Fuel return
7
14 12 Fuel inlet
13 Retaining nut
14 Gas-exchange valve